Texas Instruments BoosterPack AM2 BLDC Series User manual

EVM User's Guide: BP-AM2BLDCSERVO
AM2x BLDC Servo Motor BoosterPack (BP-
AM2BLDCSERVO)
Description
The AM2x BLDC Servo Motor BoosterPack (BP-
AM2BLDCSERVO) is an add-on for the Sitara
AM2x MCU LaunchPad development boards which
provides a networked, industrial BLDC servo
development platform. Compatible with the AM243x
(LP-AM243) and the (AM263x) LP-AM263 LaunchPad
development boards, this BoosterPack provides up to
two axes BLDC 3-phase motor drive, in-phase current
feedback, Sigma-Delta current feedback, industrial
absolute encoder, and a single axis of resolver
feedback.
The attached AM2x LaunchPad natively provide an
array of industrial Ethernet, CAN, UART, LIN and
other connectivity and control peripherals of the AM2x
MCU. Together this LaunchPad and BoosterPack
system provide a complete platform for prototyping
networked, industrial BLDC servo drives.
Get Started
Texas Instruments™ offers the MCU+ Academy as
a resource for designing with the MCU+ software
and tools on supported devices. The MCU+ Academy
features easy-to-use training modules that range from
the basics of getting started to advanced development
topics.
Features
• BOOST-XL TI BoosterPack Design - 80 digital/
analog I/O compatible with AM2x LaunchPad
Development Kits
• Two axes of 3-phase BLDC motor drive with the
DRV8316R 24 V/8A monolithic gate drive and
amplifier bridges
• Two axes (6 channels) of 3-phase current
feedback through AMC1035D Sigma-Delta
modulator and INA241A current sense path
• Two axes of RS-485 based absolute encoder
feedback supporting multiple industrial encoder
standards
• Single-axis of resolver feedback
Applications
•Servo drive communication module
•Servo drive control module
•Servo drive position feedback
•Servo drive position sensor
•Servo drive power stage module
LP-AM243 LaunchPad Attached to BP-AM2BLDCSERVO BoosterPack
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1 Evaluation Module Overview
1.1 Introduction
The BP-AM2BLDCSERVO BoosterPack kit, when attached to a compatible AM2x MCU LaunchPad MCU board,
provides an industrial BLDC servo drive development platform.
A reference software/hardware solution based on the AM243x (ALX) 2-axis servo reference system is shown in
the figure below. Together the BP-AM2BLDCSERVO and the LP-AM243 LaunchPad can be used to experiment
with this and similar networked industrial servo drive architectures.
Figure 1-1. AM243x Based BLDC Motor Drive - 2-Axis BLDC Servo Scenario
By using the AM2x dual-R5F cores along with the Programmable Real-time Unit (PRU) cores, the AM2x MCU
are able to create a flexible hardware and software architecture. This supports a wide range of industrial
real-time Ethernet standards and industrial absolute encoder standards while also taking care of the core control
loop and monitoring tasks.
1.2 Kit Contents
The only item that comes with this kit is the BP-AM2BLDCSERVO PCB assembly itself.
Additional required components, per motor axis (not included in this kit):
• 24 V (nominal), 8A (max) bench DC supply
• 3-Phase, BLDC motors - maximum 8A (RMS) current draw
• Absolute position encoders running on EnDat22, HDSL, or Tamagawa protocols
If you have any feedback or questions, support for the Sitara MCU and this BP-AM2BLDCSERVO kit is provided
by the TI Product Information Center (PIC) and the TI E2E™ Forum. Contact information for the PIC can be
found on the TI website. Additional device-specific information can be found in the Section 5.
1.3 Specification
The BP-AM2BLDCSERVO is divided up into axis-1 and axis-2 component channels with a few common system
components. All motor control I/O from the attached MCU are passed through the BoosterPack headers. Screw
terminals are used to provide a quick attachment point for bench DC power and attaching BLDC motor drive
output.
Axis-1 and axis-2 channels both include a DRV8316 BLDC 3-phase motor driver, RS-485 transceiver set
for 2-wire and 4-wire absolute encoder communication, and AMC1035D based Sigma-Delta current feedback
channels for each 3-phase motor driver output.
Additionally, axis-1 includes direct INA241A current sense amplifier feedback channels for MCU ADC sampling
and a resolver excitation and receiver amplifier network.
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The encoder RS-485 transceivers and resolver amplifier I/O are routed to Dsub15 female connectors and
optional 100-mil pitch headers that are routed in line with minimal distance between them. This gives a standard
connector interface as well as the flexible prototyping headers to account for different encoder and resolver
pinouts.
Figure 1-2. BP-AM2BLDCSERVO System Block Diagram
1.4 Device Information
This BoosterPack is part of the LaunchPad development kit ecosysem for Sitara™ Microcontrollers Family of
Arm® Cortex®-R based high performance microcontrollers. With advanced networking, real-time control, and
signal processing accelerators these MCU meet the emerging and dynamic requirements for industrial and
automotive applications.
This BoosterPack is intended to operate with the Sitara Microcontrollers - LaunchPad Evaluation Modules. TI
provides device-specific Evaluation Module (EVM) designs to help kick-start product development. See the
AM263x LaunchPad and AM243x LaunchPad for more information.
The following list highlights the primary devices used in the design of this BoosterPack evaluation kit.
•DRV8316: 40-V max 8-A peak 3-phase motor driver with integrated current sensing. This device is used to
provide the MCU with a motor drive bridge network to drive the attached 3-phase BLDC motors.
•INA241A: -5-V to 110-V bidirectional ultraprecise current sense amplifier with enhanced PWM rejection. An
array of INA241A are used as the shunt current sense amplifier to provide 3-phase current feedback from the
DRV8316 motor driver.
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•AMC1035: Precision delta-sigma modulator with ±1-V bipolar input and 2.5-V reference output. An array of
AMC1035 are used to provide a Sigma-Delta digital modulation for the current sense feedback.
•LMK1C1108: 8-channel output LVCMOS 1.8-V buffer. Used to distribute Sigma-Delta clocks from the
attached MCU to the array of AMC1035 modulators.
•THVD1450D: 3.3-V to 5-V RS-485 transceiver with ±18-kV IEC ESD protection. Multiple THVD1450 are used
to provide RS-485 transceiver and line-driver capability for the 3.3V MCU absolute encoder interfaces.
•LM74502: 3.2-V to 65-V industrial RPP controller with load disconnect and OVP. These devices are used to
provide over-voltage and reverse-polarity protection to the motor and encoder distribution network.
Many other devices were used in the construction of this evaluation kit as well. Please see the BP-
AM2BLDCSERVO Board Design Files for details.
1.5 Important Usage Notes
Thermal Warning
Note
The BP-AM2BLDCSERVO includes two motor driver amplifier devices, U6 and U7 (Texas Instruments
Part Number DRV8316RRGFR) which can exceed 55 C case temperature during normal operation.
The following additional PCB silkscreen and this user's guide statement has been added to alert users
to these higher temperature components.
Caution
Caution hot surface.
Contact can cause burns.
Do not touch!
Mechanical Warning
Note
This kit assembly does not include any mechanical components. However, normal usage of this
assembly requires attaching motors, encoders and resolvers to compatible terminals and connectors
of the board.
!
Warning
Warning: Moving parts.
Do not touch the spinning disk or motor
during operation.
TI has not performed specific safety assessments on motor, encoder or resolver components that is used with
this kit. Users of this kit are advised to follow all usage, maintenance and safety recommendations provided
by the selected accessory component manufacturers. Caution must observed in the usage of all accessory
components.
Power Supply Usage
Note
The BP-AM2BLDCSERVO requires up to two external power supplies to function. No power supplies,
cables or adapters are included in this kit.
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Note
External Power Supply Requirements:
• J5 and J6 terminal blocks (Phoenix Contact Part Number 1711725) are used as power input
• J5 and J6 terminal blocks accept 12-30 AWG wire. Multistranded 16 AWG, or larger diameter,
recommended.
• Input voltage: 9-24 Volts (nominal), 36 Volts (max)
• Max input current: 8 Amps
Note
TI recommends using an external power supply or accessory which complies with applicable regional
safety standards such as (by example) UL, CSA, VDE, CCC, PSE.
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2 Hardware
2.1 Assembly Instructions
The following assembly steps must be followed when starting with a new BP-AM2BLDCSERVO BoosterPack
and a new LP-AM2x LaunchPad.
1. BP-AM2BLDCSERVO and LP-AM2x LaunchPad are both powered down.
2. BP-AM2BLDCSERVO and LP-AM2x LaunchPad can be attached through their LaunchPad connectors.
3. Attach LP-AM2x LaunchPad power and debugging cable (if necessary) and keep LaunchPad unpowered.
4. Attach 24 V DC supply (current limit to 8A) to the BoosterPack screw terminals and keep supply powered off.
5. Attach motor drive output to the BoosterPack screw terminals.
6. Attach encoder power/data cable/wires to the BoosterPack Dsub15 connectors or 100-mil pitch headers.
7. Attach resolver power/data cable/wires to the BoosterPack Dsub15 connectors or 100-mil pitch headers.
8. Verify that all motor and encoder shafts are free and clear of obstructions prior to powering on and testing
system.
Figure 2-1. LP-AM243 mated to BP-AM2BLDCSERVO
2.2 Power Requirements
After assembly, the following power-on and power-off sequence must be followed when working with the BP-
AM2BLDCSERVO kit.
The LP-AM2x 5.0V and 3.3V BoosterPack pins provide system-level 5.0V and 3.3V power for the attached
BP-AM2BLDCSERVO kit, including indicator LED power and various logic-default pull-up resistor voltages.
Power-On Sequence
Follow the steps below to power on the device:
1. Power on the LP-AM2x LaunchPad.
2. Power on the 24 V DC supply for the BoosterPack.
3. Load and run LP-AM2x LaunchPad application over attached XDS110 debugger and Code-Composer
Studio debug session.
Power-Off Sequence
Follow the steps below to power off the device:
1. Power-off the 24V DC supply for the BoosterPack.
2. Power-off the LP-AM2x LaunchPad.
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2.3 Interfaces
Major Components and Location
The below figures show the location of major connectors, components and circuit functions used on this design.
BP-AM2BLDCSERVO Top View, Major Component Areas and Connectors Highlighted
Figure 2-2. BP-AM2BLDCSERVO Top View, Major Component Areas and Connectors Highlighted
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Figure 2-3. BP-AM2BLDCSERVO Bottom View, Major Component Areas and Connectors Highlighted
Figure 2-4. BP-AM2BLDCSERVO Top View - Connectors and Cables Overview
Typical Usage
A typical setup for an axis-1, BLDC motor control scenario is shown below. The bench power, motor drive output
and absolute encoder cables are shown attached. The attached LP-AM243 is shown with USB-C power and
XDS110 debugger cable also attached.
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Figure 2-5. BP-AM2BLDCSERVO and LP-AM243 LaunchPad - Axis-1 Power, Motor and Encoder cables
attached
2.4 LaunchPad Specific Features
Based on available LaunchPad I/O pinout, and specific MCU peripheral availability, each AM2x LaunchPad
supports a subset of the overall available features made available by this BP-AM2BLDCSERVO BoosterPack.
Additionally, only a subset of available hardware features have been fully incorporated into the AM243
and AM263 MCU SDK or made available through demo application through dev.ti.com. These supported,
unsupported and future features are outlined in the tables below. These tables are updated a new features are
tested and made available.
Table 2-1. Currently Supported Features
Feature AM243x LaunchPad
LP-AM243 Rev E3
AM243x LaunchPad
LP-AM243 Rev A
Axis-1 BLDC Driver Yes Yes
Axis-2 BLDC Driver No Yes
Axis-1 SDFM Current Feedback Yes Yes
Axis-2 SDFM Current Feedback No Yes
Axis-1 Current Feedback No No
Axis-2 Current Feedback No No
Axis-1 Absolute Position Encoder Yes Yes
Axis-2 Absolute Position Encoder No Yes
Axis-1 Resolver Position No No
The below table captures the planned features as testing, MCU SDK development and demo application work
continue with this kit.
Table 2-2. Planned/Future Features
Feature AM263x LaunchPad
LP-AM263 Rev E2
AM263x LaunchPad
LP-AM263 Rev A
Axis-1 BLDC Driver Yes Yes
Axis-2 BLDC Driver No Yes
Axis-1 SDFM Current Feedback Yes Yes
Axis-2 SDFM Current Feedback No Yes
Axis-1 Current Feedback No No
Axis-2 Current Feedback No No
Axis-1 Absolute Position Encoder Yes Yes
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Table 2-2. Planned/Future Features (continued)
Feature AM263x LaunchPad
LP-AM263 Rev E2
AM263x LaunchPad
LP-AM263 Rev A
Axis-2 Absolute Position Encoder No Yes
Axis-1 Resolver Position No No
2.5 Jumper Information
This section describes the jumper selectable options on this board. See table and figures below for list of
available jumper options, details and configuration defaults. Additional jumper details are located in each the
major
Note
These static jumper configurations must be checked and set prior to running different motor control
scenarios.
Figure 2-6. Layout Top View - Jumper Locations
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